Aluminum Alloy Castings
Properties, Processes And Applications
J. Gilbert Kaufman, Elwin L. Rooy
SELECTED CONTENTS
Chapter 1: Introduction
- Background and Scope
- History
- Advantages and Limitations of Aluminum Castings
- Major Trends Influencing Increased Use of AluminumCastings
- Technology
- Recycling
- Selecting the Right Aluminum Alloy and Casting Process
Chapter 2: Aluminum Casting Alloys
- GeneralSpecifications
- Alloy Designations
- The Aluminum Association (AA) Casting AlloyDesignation System
- Aluminum Association Casting Temper DesignationSystem
- Evolution of Designation System; Cross-Reference toOlder Designations
- The UNS Alloy Designation System
- International Casting Alloy Designations
- Nomenclature System for Aluminum Metal-MatrixComposites
- Composition Groupings
- Aluminum-Copper
- Aluminum-Silicon-Copper
- Aluminum-Silicon
- Aluminum-Silicon-Magnesium
- Aluminum-Magnesium
- Aluminum-Zinc-Magnesium
- Aluminum-Tin
- Effects of Alloying Elements
- Antimony
- Beryllium
- Bismuth
- Boron
- Cadmium
- Calcium
- Chromium
- Copper
- Iron
- Lead
- Magnesium
- Manganese
- Mercury
- Nickel
- Phosphorus
- Silicon
- Silver
- Sodium
- Strontium
- Tin
- Titanium
- Zinc
- Alloy Groupings by Application or Major Characteristic
- General-Purpose Alloys
- Elevated-Temperature Alloys
- Wear-Resistant Alloys
- Moderate-Strength Alloys with Low Residual Stresses
- Bearings
- High-Strength Alloys
Chapter 3: Aluminum Casting Processes
- History
- Casting Process Selection
- Casting Design
- Specification Requirements
- Volume of Production
- Costs
- Quality
- Casting Process Technology
- Expendable and Nonexpendable Mold Processes
- Pressure versus Gravity
- Gating and Risering
- Expendable Mold Gravity-Feed Casting Process and Its Variations
- Sand Casting
- Evaporative (Lost-Foam) Pattern Casting (EPC)
- Shell Mold Casting
- Plastic Casting
- Investment Casting
- Vacuum Mold (V-Mold) Casting
- Nonexpendable (Permanent) Mold Gravity Feed Casting Process and Its Variations
- Permanent Mold Casting
- Low-Pressure Die Casting (LP), Pressure Riserless Casting (PRC)
- Vacuum Riserless Casting (VRC)
- Centrifugal Casting
- Squeeze Casting
- Semisolid Forming
- Pressure Die Casting and Its Variations
- Acurad Die Casting Process
- High-Integrity Pressure Die Casting
- Pore-Free Pressure Die Casting
- Vacuum Die Casting
- Rotor Casting
- Premium Engineered Castings
- Melt Processing
- Melt Quality Assessment
- Solidification
- Solidification Rate
- Mold Materials
- Alloys
- Aluminum-Silicon Eutectic Modification and Grain Refinement
- Mold Filling
- Quality Assurance
- Relevance of Premium Casting Engineering
- Other Process Technologies
- Metallurgical Bonding
- Cast Aluminum-Matrix Composites
- Hot Isostatic Pressing (HIP)
Chapter 4: The Effects of Microstructure on Properties
- Intermetallic Phases
- Dendrite Arm Spacing
- Grain Refinement
- Aluminum-Silicon Eutectic Modification
- Refinement of Hypereutectic Aluminum-Silicon Alloys
Chapter 5: The Influence and Control of Porosity and Inclusions in Aluminum Castings
- Hydrogen Porosity
- Shrinkage Porosity
- Inclusions
- Combined Effects of Hydrogen, Shrinkage, and Inclusions
- Radiographic Inspection
Chapter 6: Hot Isostatic Pressing
- The HIP Process
- The Effect of HIP on Tensile Properties
- The Effect of HIP on Fatigue Performance
- Radiographic Inspection of HIPped Castings
Chapter 7: Heat Treatment of Aluminum Castings
- Solution Heat Treatment
- Quenching
- Precipitation Heat Treating/Aging
- Aluminum-Copper
- Aluminum-Copper Magnesium
- Aluminum-Silicon-Magnesium
- Aluminum-Zinc-Magnesium
- Annealing
- Stability
- Residual Stresses
- Troubleshooting Heat Treatment Problems
- Acceptance Criteria
- Diagnosis
Chapter 8: Properties and Performance of Aluminum Castings
- Compositions and Influence of Composition on Characteristics
- Physical Properties of Aluminum Casting Alloys
- Typical and Minimum Mechanical Properties of Aluminum Alloy Castings
- Published Typical Mechanical Properties
- Published Minimum and Design Mechanical Properties
- Effects of Subzero and Elevated Temperatures on Mechanical Properties
- Influence of Premium Practices and Emerging Casting Technologies on Mechanical Properties
- Fatigue Properties of Aluminum Casting Alloys
- Influence of Casting Quality on Fatigue Strength
- Influence of Stress Raisers on Fatigue Strength of Aluminum Castings
- Fatigue Strengths of Welded Aluminum Castings
- Design Fatigue Strengths for Aluminum Castings
- Fracture Resistance of Aluminum Alloys
- Notch Toughness and Notch Sensitivity
- Tear Resistance
- Fracture Toughness
- Interrelation of Measures of Fracture Resistance
- Subcritical Crack Growth
- Fatigue Crack Growth
- Creep Crack Growth
- Stress-Corrosion Crack Growth
- Corrosion Resistance
- Aluminum-Copper Casting Alloys (2xx.x)
- Al-Si-Cu and/or Mg Casting Alloys (3xx.x)
- Aluminum-Silicon Casting Alloys (4xx.x)
- Aluminum-Magnesium Casting Alloys (5xx.x)
- Aluminum-Zinc Casting Alloys (7xx.x)
- Aluminum-Tin Casting Alloys (8xx.x)
- Properties of Cast Aluminum Matrix Composites
